CN1677130A - Manufacturing method of optical substrate - Google Patents

Abstract

A method for manufacturing an optical substrate comprises the following steps: (A) heating a first material and a second material to a molten state; (B) stacking the first material and the second material together; (C) pressurizing the first material and the second material to form a substrate having a predetermined width and a predetermined thickness; (D) forming a predetermined surface texture on the surface of the second material; (E) cooling the substrate; and (F) cutting the substrate.

Description

Manufacturing method of optical substrate

technical field

The present invention relates to optical elements, in particular to a method for manufacturing an optical base material.

Background technique

The existing direct-type backlight module includes a frame on which a reflective sheet, a plurality of lamp tubes and a diffuser plate are sequentially installed. The light sources of the lamp tubes are directly irradiated to the diffuser plate, and part of the light sources It is directed to the reflective sheet, and is set to the diffuser plate through reflection of the reflective sheet. The diffusion plate diffuses the passing light source to form a uniform surface light source.

In the diffusion plate, a diffusion film, a prism film and a light enhancement film are sequentially pasted on a substrate. The cost of these optical films is not only expensive, but also the process of attaching the films still relies on manual work, which increases the work cost.

In addition, an adhesive layer must be coated between each layer of films, so that the films are sequentially pasted on the transparent substrate. Therefore, whether the adhesive layer is coated evenly and whether the pressure of each film is evenly applied are all important factors that affect the optical properties of the diffuser plate, in addition to the size and optical properties of each film. However, relying on the manual work of attaching, the good rate of conventional diffusion plates is not good.

Contents of the invention

The main purpose of the present invention is to provide a method for manufacturing an optical substrate, which is easy to manufacture and has a high yield.

In order to achieve the aforementioned object of the invention, a method for manufacturing an optical substrate provided by the present invention includes the following steps:

heating a first material and a second material to a molten state;

stacking the first material and the second material together;

pressurizing the first material and the second material to form a substrate having a predetermined width and a predetermined thickness, and

A predetermined surface texture is formed on the surface of the second material.

Description of drawings

Fig. 1 is the flowchart of the first preferred embodiment of the present invention;

Fig. 2 is the cross-sectional view of the first optical substrate produced by the method according to the first preferred embodiment of the present invention;

3 is a cross-sectional view of a second optical substrate produced by the method according to the first preferred embodiment of the present invention;

4 is a cross-sectional view of a third optical substrate produced by the method according to the first preferred embodiment of the present invention;

Fig. 5 is the flowchart of the second preferred embodiment of the present invention;

6 is a cross-sectional view of the first optical substrate produced by the method according to the second preferred embodiment of the present invention;

FIG. 7 is a cross-sectional view of a second optical substrate manufactured by the method according to the second preferred embodiment of the present invention.

Specific implementation

Please refer to FIG. 1, the manufacturing method of the optical substrate provided by the first preferred embodiment of the present invention includes the following steps:

(A) Heating a first material and a second material to a molten state.

The first material is a plastic particle containing diffusion particles, which can be polymethyl methacrylate (Polymethyl methacrylate, PMMA), polycarbonate (Polycarbonate, PC) or cycloolefin polymer (Cyclic Olefins Polymer, COP) and other materials. The second material is transparent plastic particles. It can be polymethyl methacrylate (PMMA), polycarbonate (PC) or cycloolefin polymer (Cyclic Olefins Polymer, COP) and other materials.

(B) injecting the molten first material and a second material into an adapter, so that the second material is stacked on the first material.

The connector has the function of determining the thickness ratio of the first material and the second material.

(C) injecting the first material and a second material into a die head to expand it into a base material with a predetermined width.

(D) Rolling the substrate flowing out of the die to a predetermined thickness by using a roller calender. The pressing roller has a predetermined groove, so when it rolls the second material of the substrate, it will form a predetermined surface profile on the surface of the second material.

(E) Cooling the rolled substrate to solidify it.

(F) Cutting the substrate.

According to the above-mentioned method, the base material is completed in a continuous process, and there is no need to manually attach the diffusion film and the light-collecting film, so the yield of the product and the simplicity of the process will be improved. The thickness of the base material produced according to the method can be more than 0.5mm, and the preferred thickness is 1mm to 5mm. The thickness of the second material can be more than 1 μm, preferably 50 μm to 200 μm.

Please refer to Fig. 2, the optical substrate 10 manufactured through the aforementioned steps has a first layer 12 and a second layer 14, wherein the first layer 12 is formed by the first material, and the second layer Layer 14 is formed from the second material. The first layer 12 has diffusion particles 16 for diffusing light, and the surface of the second layer 14 has surface textures 18 to form a prism. In other words, the first layer 12 of the optical substrate 10 functions like a conventional diffuser, and the second layer 14 functions like a prism film, but there is no adhesive layer between the two layers to bond them together.

In the aforementioned manufacturing steps, the surface of the first material can also be embossed with a predetermined surface texture during the rolling process of step (D), so that the optical substrate 20 manufactured in this way, as shown in FIG. 3 , has A first layer 22 and a second layer 24 , wherein the first layer 22 has a first surface texture 26 on its surface, and the second layer 24 has a second surface texture 28 on its surface. The first surface texture 26 provides the function of diffusion, and the second surface texture 28 provides the function of light collection.

In the optical substrate shown in FIG. 3 , the first layer 22 also has diffusion particles 30 inside, which can further enhance the function of diffusion. Of course, since the first surface texture 26 already has the function of diffusion, the first layer may not have diffusion particles. However, in the manufacturing steps, it is only necessary to select the first material as a general material without diffusion particles.

In addition, in step (B), after the molten first material and a second material are injected into an adapter, the adapter arranges the second material on both sides of the first material respectively, The optical substrate 32 thus formed, as shown in FIG. 4 , has a first layer 34 and two second layers 36 respectively located on two sides of the first layer 34 . The surfaces of the two second layers 36 respectively have a surface texture 38 , 40 . The second material forming the second layer 36 can be a material with low water absorption, such as Cyctic Olefins Polymer (COP) or Cyclic Olefins Copolymer (COC).

It should be noted here that, in this preferred embodiment, the surface texture formed on the optical substrate is carried out simultaneously with the rolling step, step (D). In practice, in step (D), the optical substrate can be rolled to a predetermined thickness, and after the optical substrate is cooled, the known calender printing process, screen printing process, yellow light process or Other methods do secondary processing to complete.

Please refer to FIG. 5, the manufacturing method of the optical substrate provided by the second preferred embodiment of the present invention, the optical substrate has three layers, including the following steps:

(A) heating a first material, a second material and a third material to a molten state.

(B) injecting the molten first material, the second material and the third material into a die head with multiple channels, so that the third material and the second material are sequentially stacked on the first material , and stretch it into a substrate with a predetermined width.

(C) Rolling the base material flowing out of the die head to have a predetermined thickness by using a first pressing roller set.

(D) Utilizing a second set of calendering rollers having a predetermined groove so that when it is rolling the second material of the base material, a surface texture is formed on the surface of the second material (surface profile).

(E) Cooling the rolled substrate to solidify it.

(F) Cutting the substrate.

6, the optical substrate 42 manufactured through the aforementioned steps has a first layer 44, a second layer 46 and a third layer 48, wherein the third layer 48 is located between the first layer 44 and the second layer. Between layers 46. The first layer 44 is formed of the first material, the second layer 46 is formed of the second material, and the third layer 48 is formed of the third material. The first layer 44 is a transparent substrate, the third layer 48 has diffusion particles 50 for diffusing light, and the surface of the second layer 46 has surface textures 52 to form a prism. A surface texture (not shown) can also be formed on the surface of the first layer 44 on the aforementioned optical substrate 42 .

In the manufacturing method of the second preferred embodiment, the first material, the second material and the third material have different material properties, for example: a material with high transparency, a material with diffused particles therein, a low water absorption Sexual materials or highly reflective materials, etc., so that the optical plate can provide better optical effect.

In step (B), the second material and the third material can be arranged on both sides of the first material, please refer to FIG. 7, the optical substrate 54 has a first layer 56, a second layer 58 and a third layer 60 , wherein the first layer 56 is located between the second layer 58 and the third layer 60 . The first layer 56 has diffusion particles 62 , the second layer 58 has surface textures 64 , and the third layer 60 is made of highly reflective material to function as a reflective film.

In step (D), a surface texture can also be embossed on the third layer to form a structure similar to that shown in FIG. 4 . It is just that the second layer 58 and the third layer 60 on both sides of the first layer 56 are formed of different materials.

According to the same principle, four (or more than four) different materials can be added to form together in the manufacturing method of the present invention. The manufactured optical substrate may have four layers (or more than four layers) and be stacked together in a predetermined order.

Claims (13)

1. the manufacture method of an optical element is characterized in that including the following step:

Heat one first material and one second material to molten condition;

With this first material and this second material stacks together;

Pressurize this first material and this second material make it to form a base material with a preset width and a predetermined thickness;

At the predetermined surface pattern of the shaping surface one of this second material;

Cool off this base material, and

Cut this base material.

2. according to the manufacture method of the described optical element of claim 1, it is characterized in that: wherein this second material is stacked on respectively on the two opposite sides of this first material.

3. according to the manufacture method of the described optical element of claim 2, it is characterized in that: wherein include on the surface of second material that is positioned at these first material both sides and be formed separately a surface pattern.

4. according to the manufacture method of the described optical element of claim 1, it is characterized in that: wherein have diffusion particle in this first material.

5. according to the manufacture method of the described optical element of claim 1, it is characterized in that: wherein include the surface pattern of being scheduled at the shaping surface one of this first material.

6, the manufacture method according to the described optical element of claim 1 is characterized in that: wherein pressurize this first material and this second material are finished simultaneously with the step at the shaping surface surface pattern of this second material.

7. the manufacture method of an optical element is characterized in that including the following step:

Heat one first material, one second material and one the 3rd material to molten condition;

With this first material, this second material and the 3rd material stacks together;

Pressurize this first material, this second material and the 3rd material make it to form a base material with a preset width and a predetermined thickness;

At the predetermined surface pattern of the shaping surface one of this base material;

Cool off this base material, and

Cut this base material.

8. according to the manufacture method of the described optical element of claim 7, it is characterized in that: wherein the 3rd material stacks is on this first material, and this second material stacks is on the 3rd material.

9. according to the manufacture method of the described optical element of claim 7, it is characterized in that: wherein this second material and the 3rd material are stacked on respectively on the two opposite sides of this first material.

10. according to the manufacture method of the described optical element of claim 8, it is characterized in that: wherein more include shaping surface one surface pattern at this first material.

11. the manufacture method according to the described a kind of optical element of claim 9 is characterized in that: wherein more include shaping surface one surface pattern at the 3rd material.

12. the manufacture method according to the described optical element of claim 7 is characterized in that: wherein pressurize this first material and this second material are finished simultaneously with the step at the shaping surface surface pattern of this second material.

13. the manufacture method of an optical element is characterized in that including the following step:

Heat one first material and one second material to molten condition;

With this first material and this second material stacks together, and extend this first material and this second material to a preset width;

Pressurize this first material and this second material make it to form a base material with a predetermined thickness, and

At the predetermined surface pattern of the shaping surface one of this second material.

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